Stratasys Ltd has announced that UK medical 3D printing
specialist, Replica 3DM, is using its Stratasys 3D Printers to
provide a service to twelve NHS hospitals to print models for the
validation of reconstructive implants prior to surgery.

The 3D modelling is having a significant impact on the length of
surgical procedures and leading to substantial reductions in theatre
costs.

Replica 3DM's Stratasys Objet24 and Objet30 Pro 3D Printers
convert patient CT scans into physical 3D printed models that are
used as surgical guides to test implants for size and fit
pre-surgery. This includes re-bending of titanium implant plates to
the patient's exact specifications and preoperative investigations
across maxillofacial, orthopedics, neurology, spinal and ears, nose
and throat wards, to identify the correct procedure and improve
outcome.

The company also produces a number of cranioplasty models in
which the unaffected side of the patient's face is mirrored to
produce a 3D printed reconstruction, prior to the fitting and
placement of a titanium plate.

Originally established as a 3D modelling department of Salisbury
District Hospital, Replica 3DM has since extended its medical 3D
printing capabilities to NHS hospitals across the UK, primarily
offering its services to trusts that do not have in-house access to
3D printers.

"To us, 3D printing and the medical profession go hand-in-hand,
particularly in the planning of complicated procedures," explains
Matthew Sherry, Managing Director and Founder of Replica 3DM. "A 3D
model equips surgeons with a hands-on perspective which cannot be
achieved by looking at a computer screen. They can easily rotate,
inspect and analyze each surgical procedure on a case-by-case basis,
enabling them to pre-bend implants knowing that they will perfectly
fit the patient. This is instrumental in eliminating potential
problems during operations and can be used as a visual aid when
explaining the surgical procedure to patients."

Examples of 3D printing

According to Matthew Sherry, the ability to use 3D printed models
to pre-bend titanium implants has reduced surgery time
significantly.

"In the past, surgeons would depend on surgical experience to fit
the plates during surgery. This could not only be quite costly, it
may also crucially require longer patient anaesthesia times," he
explains. "As demonstrated in a recent maxillofacial procedure at
Salisbury District Hospital, the ability to pre-bend the titanium
plate prior to surgery enabled surgeons to secure the perfect custom
fit. This reduced the number of incisions required and overall
theatre time, directly impacting the quality of patient care.

"With theatre typically costing around £3,600 an hour, you can
imagine how much we save NHS Trusts. In most cases, a model will pay
for itself and helps with essential pre-operative surgical
planning."

Chris Baker, Stratasys Northern European Territory Manager,
explains: "In an industry where precision is paramount, the ability
to produce highly accurate 3D printed surgical models and guides
that mimic the look and feel of titanium implants can both lower
costs and reduce the time required for patients to be anesthetised.
As a result, an increasing number of hospitals worldwide are
integrating 3D printing into surgical planning procedures, which is
having an immediate positive impact on the quality of patient
treatment."